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Mailmans , 77D getting a makeover
- Thread starter Mailman
- Start date
I changed some tires for a guy on a Honda V twin. This bike was assembled at the dealer, out of the crate, with the vent hose pinched between the tank and the frame. Because of this the tank was all sucked in and dented, Honda and the dealer would not even discuss this with him. I blocked the gas cap hole and plumbed the petcock to attach to an air hose. I put 60 psi into the tank, dents popped out, looked pretty good. 20 bucks per tire and free dent removal, he was a happy guy.
Scott
Scott
So the side covers that Jim painted for me?
They got the acid test today. One of my new petcocks has a small leak and I didn’t realize it until a couple hours after I just got back from a long ride. Gas blew back and streaked down the side of my left cover. I just finished washing it and hit it with a little detailer spray.
Does that look damaged to you?
Here is an extreme close up!
Unreal! Looks like a mirror! Jim rocks!
They got the acid test today. One of my new petcocks has a small leak and I didn’t realize it until a couple hours after I just got back from a long ride. Gas blew back and streaked down the side of my left cover. I just finished washing it and hit it with a little detailer spray.
Does that look damaged to you?
Here is an extreme close up!
Unreal! Looks like a mirror! Jim rocks!
Last edited:
Today I got started on a couple of small projects. First up , I need to address the brand new leaky petcocks 
And I was trying to be so careful with those too. Before I mounted them I cleaned the mating surface on the gas tank really well, I removed all paint and had a clean metal surface to mount the petcocks to. I also broke down the petcocks, even though they were new to inspect them. I upgraded the sealing washers and mounting screws, I put Hylomar on the sealing gasket on the flat plate on the back sides
And still they leaked! Streaming gas across my freshly painted side covers to boot! Well the side covers are in good shape, Jim used a really high quality paint on them, they cleaned right up.
So first I had to drain the tank and remove the petcocks.
I haven’t broke these down yet, but they appear to be leaking from the one thing I didn’t touch, these red fiber washers, I figured they would be the least of my problems and would seal well. But that would be wrong. Oh and remember when I super glued my filters on to the end of the brass pick up tubes ? Yeah that’s them. They were rattling around inside my tank.
Also while the paint on my side covers was impervious to gasoline, apparently the one thing that is designed to hold gas, is not! I noticed a line of what I thought was grease or oil and when I wiped it, the paint just wiped right off! Crap!
I also wanted to change out my yellow spark plug wires, I never liked them. And I like them even less now that I have this all black bike.
So, maybe tomorrow, I’ll get some new wires made up and go through my petcocks yet again.
“There are always two choices, two paths to take. One is easy. And it’s only reward is that it’s easy.”
I never seem to take the easy path.
John Lee Hooker and Van Morrison,
It serves me right to suffer.
Later,
Bob
And I was trying to be so careful with those too. Before I mounted them I cleaned the mating surface on the gas tank really well, I removed all paint and had a clean metal surface to mount the petcocks to. I also broke down the petcocks, even though they were new to inspect them. I upgraded the sealing washers and mounting screws, I put Hylomar on the sealing gasket on the flat plate on the back sides
And still they leaked! Streaming gas across my freshly painted side covers to boot! Well the side covers are in good shape, Jim used a really high quality paint on them, they cleaned right up.
So first I had to drain the tank and remove the petcocks.
I haven’t broke these down yet, but they appear to be leaking from the one thing I didn’t touch, these red fiber washers, I figured they would be the least of my problems and would seal well. But that would be wrong. Oh and remember when I super glued my filters on to the end of the brass pick up tubes ? Yeah that’s them. They were rattling around inside my tank.
Also while the paint on my side covers was impervious to gasoline, apparently the one thing that is designed to hold gas, is not! I noticed a line of what I thought was grease or oil and when I wiped it, the paint just wiped right off! Crap!
I also wanted to change out my yellow spark plug wires, I never liked them. And I like them even less now that I have this all black bike.
So, maybe tomorrow, I’ll get some new wires made up and go through my petcocks yet again.
“There are always two choices, two paths to take. One is easy. And it’s only reward is that it’s easy.”
I never seem to take the easy path.
John Lee Hooker and Van Morrison,
It serves me right to suffer.
Later,
Bob
Last edited:
Bob, I smeared some Hylomar on the screw threads and the fiber washer they use. I also didn't clean the paint off the tank at the petcock mounting flats. The only part that leaked was the Motion Pro fuel line! It was/is too large (loose fit) even at 1/4" and clamped. Changed it with some clear 1/4" from Home Depot.
Good luck with your fix.
Good luck with your fix.
Van the Man and John lee, without question my two most favourite artists .I'm just not sure how successful this session was . Van has a unique singing style and his rythm isn't what you'd call Blues really. When Van starts singing it almost seems like an unwanted intrusion into Johns silky smooth, soulfull tones.
I just love the quality of the paint finish on your tank Bob. Its gorgeous. When i compare it to the rubbish rattle can finish on my tank it makes me feel ashamed that I'm such a cheapskate at times
I hate it when a bike pisses gas all over itself and onto the garage floor...
There’s no doubt about it - XS650 petcocks can be infuriatingly prone to leaking.
My advice is Hylomar Blue and once you get them sealed - DO NOT TOUCH THEM!
Pete
My advice is Hylomar Blue and once you get them sealed - DO NOT TOUCH THEM!
Pete
So mailman I'm the big "scrape the paint off the mount" advocate but I'm ALSO the guy that demands you seal the raw edge with epoxy, isocyonate or such. A cut ( or tape) paint edge allows fuel to get to and be absorbed by the primer layer, the paint then will bubble.
Is there a particular epoxy you like to use for that?
Nah What ever I have around, usually some clear two part epoxy glue. I do this at the petcocks AND at the gas cap. Even Pro painters just masking tape the holes leaving that thick, primer exposed, edge. I knife and or sand back the paint and seal it with epoxy. Got burned once many decades ago, ruining a very sharp new paint job, never again. I tend to strip off the old paint myself even if sending out the spray job. I spend a LOT of time at the tank/filler neck seam digging out all the old gas soaked paint till nothing but shiny metal is in there.
Yeah ok, you sold me. I’m gonna run out this morning and buy some!
holy smokes Mailman another episode of leaks . You are re writing the book on sealing up XS’s ! All good , and good luck !I never seem to take the easy path.
At this point I have no idea how my own XS’ s have not leaked ! (well barely) I’ve gotten away with reusing stock gaskets somehow so many times. Tank petcock gaskets included.
Bob , Never ever buy yourself an old Porsche 911 ! Ever ..
-RT
Haha! Never had a Porsche, but I had a 1960 Chevy step side pickup, that had a super basic straight six motor and 4-speed granny low. That motor had this great big vent tube that just belched oil fumes all over the bottom of the motor , which then would drip on the ground. It never seemed to bother me, I loved that old truck, it was indestructible.
60, Oil bath air filter too ?
Hey Bob keep up the good work !
That new black/gold look really rocks on your 77,
-R
My XS2 tank was also painted over the petcock mounts, I did not remove the paint. I just couldn’t make myself scrape all that new paint off, despite Gary’s recommendation to do so. There was a big discussion on that in my XS2 thread, Gary even showed how he did it on his beautiful gold XS1 tank!
It’s in my thread during the assembly stage when I got ready to install the gas tank.Re: the extra holes, they’re not holes, you’re seeing spot welds. Also, on the black tank the petcock mounts are raised and they had no paint on them, just clear, which I scraped off.
Thanks Randy! And yes it had that big old honkin oil bath air cleaner, I loved everything about that old truck.
By the way, I never made it out to my shop today. I ran around all morning and it was too hot later.
